Fortune 100 Energy Infrastructure Provider

Fortune 100 Energy Infrastructure Provider

Company Overview

This case study outlines LEGACY’s work with a Fortune 100 energy infrastructure provider. This company has global teams designing technology solutions for the transmission, distribution, management, conversion and optimization of electrical power across multiple energy-intensive industries. They bring in over a billion dollars in revenue in over 20+ countries each year.

The Challenge:

Issues with safety, quality and efficiency within pick and consolidation processes.

Specific Challenges:

Significant safety issues within the facility due to layout, flow of work and PIT travel paths

Expanding consolidation footprint to handle batch and queue pick work

Excessive time spent matching product within orders due to significant travel waste

Unbalanced work levels between pick and consolidation processes

The Solution:

LEGACY conducted Kaizen Blitz as part of a Lean Action Workout, which was two weeks of intense focus on safety, quality, delivery, and cost for pick and consolidation processes corporate, regional, operational, associate and partner representation.

Surfaced and eliminated traffic and back safety issues with workstation redesign, re-layout and visual management and 5S techniques

Error-proofed overflow locations to remove risk of lost material

Improved prioritization of critical work through redesign of dispatch work

Developed and implemented continued learning program to ensure adoption of programs- including clear SOP documentation, individual scorecard tracking and performance management to designated productivity, safety and efficiency KPIs

The Results:

As a result of this Kaizen Blitz, efficiency was drastically improved.

Zero reported OSHA recordable incidents since Kaizen Blitz

Reduced PPM below target of 450

Sustained Rate of 363.73 through 16 weeks post-Kaizen Blitz

Established and met target of 1300 lines processed per day

Efficiency gains resulting in savings of $83,654 per annum for the operation

Reclaimed 5,292 square feet of space in the consolidation processing area

“The LEGACY team conducted Kaizen Blitz as part of a Lean Action Workout and we were proud to see efficiency gains in productivity and safety resulting in significant annual savings.”